The invention relates to a nonwoven solid material, preferably a cosmetic or dermatological nonwoven solid material, comprising a plurality of fibers, wherein said fibers comprise a body comprising at least one polymeric material and a body coating comprising at least one hydrophilic polymer, said nonwoven solid material further comprising at least one releasable cosmetic ingredient or composition. The invention relates to a face mask, a manufacturing process and applications of said nonwoven solid material or face mask.

A fiber structure includes crimped staple fibers and heat-bonding conjugate staple fibers mixed in a specific weight ratio, the heat-bonding conjugate staple fibers having, as a heat-bonding component disposed on the surface thereof, a thermoplastic resin having a melting point lower by 40 C. or more than that of a thermoplastic resin constituting the crimped staple fibers, the fiber structure having scattered fixing points in which the heat-bonding conjugate staple fibers are heat-fused and intersect together and/or scattered fixing points in which the heat-bonding conjugate staple fibers and the crimped staple fibers are heat-fused and intersect together, the fiber structure having a specified thickness and density and having a laminated structure of three or more layers, wherein the hardness ratio between an intermediate layer portion and a surface layer portion defined when the fiber structure is equally divided into three portions is 0.60 or more.

A method of forming a single piece, shaped, down feather thermally insulating article having different thermal insulating sections is described. A mold is formed with a cavity defining a non-uniformed prescribed shape and having sections of different shapes and depths. Down feather clusters or a mixture thereof is mixed with a binding material and is injected into the mold which is then heated with a suitable heat source to cause the binding material to soften and fuse the mixture together. After cooling the mold, there is formed a single piece, shaped, down feather article which is comprised of sections having different thermal insulating values for use in a product where parts of the product provide different thermal insulating properties.

The purpose of the present invention is to provide a porous shaped nonwoven fabric, which has excellent texture and good liquid permeability, is bulky, and is less susceptible to liquid return. The present invention provides a shaped nonwoven fabric with sections of relatively low specific volume and sections of relatively high specific volume present in parallel lines on the surface of the nonwoven fabric, wherein the portion with a low specific volume have thermally compressed areas alternating with porous areas and the portion with a high specific volume have ridges that have not been thermally compressed.

A meltblown nonwoven formed from a bicomponent fiber, wherein: the bicomponent fiber has a first region and a second region, the first region is formed from a first composition comprising at least 75 wt. % of a polypropylene; the second region is formed from a second composition comprising at least 75 wt. % of an ethylene/alpha-olefin interpolymer.

Disclosed is a wearable article continuous in a longitudinal direction and a transverse direction comprising an elastic belt region, a crotch region, a waist opening and two leg openings; the elastic belt region is a laminate comprising an inner sheet made of nonwoven fiber, and an outer sheet made of nonwoven fiber, and a plurality of elastic bodies configured to stretch the elastic belt region in the transverse direction, the crotch region comprises an outer cover layer at the most garment facing side, the outer cover layer being the same material as the outer sheet; wherein the outer sheet has a Compression Work of more than about 550 gfmm, a Compression Average Rigidity of less than about 500 gf/mm.sup.3, a Surface Roughness Wavelength of more than about 1.7 mm, and a Glossiness of less than about 5.3, the Compression Work, the Compression Average Rigidity, the Surface Roughness Wavelength and the Glossiness according to the measurements herein.

Nonwoven fabrics including a first spunmelt through-air-bonded (TAB) nonwoven layer comprising a first plurality of spunmelt fibers, in which the first plurality of spunmelt fibers comprise a biopolymer. The first plurality of spunmelt fibers may be physically entangled with cellulosic fibers, such by hydroentangling. Methods of forming a nonwoven fabric including a first spunmelt TAB nonwoven layer are also provided.

A bonded and entangled non-woven structure made of at least 50% staple fibers by weight of the bonded and entangled non-woven structure, and at least a partial bonding of the fibers of the non-woven structure. The at least partial bonding including thermally activated bonds between a first polyolefin material produced with a catalyst including at least one metallocene catalyst and having a melting point in the range 130-170 C. and a second material having a melting point which is at least 10 C. higher than the melting point of the first material, the weight of the first material in the non-woven structure being at least 3% of the weight of the nonwoven structure.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A nonwoven composite for high temperature applications requiring Sow flammability, smoke, and/or toxicity, including a fibrous structure having one or more nonwoven material layers including a scrim layer. The scrim is formed from inorganic fibers, at least some of which are adapted to withstand temperatures of up to about 1150 C. The scrim is formed from a wet-laying process. The composite further comprises one or more fiber matrix layers.